Cutting Conditions In milling

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106 Milling Valery Marinov, Manufacturing Technology Face milling In face milling, cutter is perpendicular to the machined surface. The cutter axis is vertical, but in the newer CNC machines it often is horizontal. In face milling, machining is performed by teeth on both the end and periphery of the face-milling cutter. Again up and down types of milling are available, depending on directions of the cutter rotation and feed. Partial face milling operation. The facemilling cutter machines only one side of the workpiece. Conventional face milling operation. The face-milling cutter machines the entire surface. The cutter diameter is greater than the workpart width. Face milling is usually applied for rough machining of large surfaces. Surface finish is worse than in peripheral milling, and feed marks are inevitable. One advantage of the face milling is the high production rate because the cutter diameter is large and as a result the material removal rate is high. Face milling with large diameter cutters requires significant machine power. End milling In end milling, the cutter, called end mill, has a diameter less than the workpiece width. The end mill has helical cutting edges carried over onto the cylindrical cutter surface. End mills with flat ends (so called squire-end mills) are used to produce pockets, closed or end key slots, etc.: End milling operation used to cut a pocket in an aluminum workpart.
Valery Marinov, Manufacturing Technology MILLING OF COMPLEX SURFACES Milling 107 Milling is one of the few machining operations, which are capable of machining complex two- and three-dimensional surfaces, typical for dies, molds, cams, etc. Complex surfaces can be machined either by means of the cutter path (profile milling and surface contouring), or the cutter shape (form milling). Form milling In form milling, the cutting edges of the peripheral cutter (called form cutter) have a special profile that is imparted to the workpiece. Cutters with various profiles are available to cut different two-dimensional surfaces. One important application of form milling is in gear manufacturing (Section 6.6). Form milling of twodimensional surface. (Left) Profile milling of a cam, and (Right) Surface contouring of a complex three-dimensional surface. Profile milling In profile milling, the conventional end mill is used to cut the outside or inside periphery of a flat part. The end mill works with its peripheral teeth and is fed along a curvilinear path equidistant from the surface profile. Surface contouring The end mill, which is used in surface contouring has a hemispherical end and is called ball-end mill. The ball-end mill is fed back and forth across the workpiece along a curvilinear path at close intervals to produce complex three-dimensional surfaces. Similar to profile milling, surface contouring require relatively simple cutting tool but advanced, usually computer-controlled feed control system. Close-up view of a hemispherical ball-end mill with indexed carbide inserts used for rough cutting of a three-dimensional surface. Surface contouring of die cavity. The cutter used is a high-speed steel ball-end mill.
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Cutting Conditions In milling

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